WHAT IS A
MANUFACTURING
EXECUTION
SYSTEM (MES)?
Introduction
A Manufacturing Execution System (MES) helps businesses ensure that their manufacturing operations and production output are working to maximum efficiency. It’s a software system that connects, monitors, and controls machines, work centers, and data flows on the factory floor. The MES does this by tracking and gathering real-time data throughout the production lifecycle and on every piece of equipment involved in the production process—from order to delivery. An MES provides businesses with data on product tracking and genealogy, performance, traceability, management, work in progress (WIP), and other plant activities throughout the production cycle. This information provides decision makers with detailed insight on how to optimize their operations. In this eBook, we’re going to take a look at:
What Does a
Manufacturing
Execution
System Do?
Manufacturing
Execution
System
Architecture
What are the
Benefits of Using
a Manufacturing
Execution System?
We’ll also cover manufacturing execution systems in detail and provide links to other resources on our website, helping you understand how this technology can create efficiency in your plant.
WHAT DOES A
MANUFACTURING
EXECUTION
SYSTEM DO?
The Manufacturing Enterprise Solutions Association (MESA) is an organization that monitors the effective application of IT to help improve operations management.
The MESA model is perhaps the most accurate definition of MES and what it does. In 1997, it was defined through 11 core functions:
1
OPERATIONS/
DETAILED
SEQUENCING
2
RESOURCE
ALLOCATION
& STATUS
3
DOCUMENT
CONTROL
4
PROCESS
MANAGEMENT
5
DATA COLLECTION
& ACQUISITION
6
QUALITY
MANAGEMENT
7
LABOR
MANAGEMENT
8
DISPATCHING
PRODUCTION
UNITS
9
PRODUCT
TRACKING &
GENEALOGY
10
PERFORMANCE
ANALYSIS
11
MAINTENANCE
MANAGEMENT
WHAT IS A MANUFACTURING EXECUTION SYSTEM (MES)? |
PAGE 3
2004
MESA
MODEL
In 2004, the MESA model was expanded to include business operations. The model shows how the core operations in the original interact with business operations, taking into account competition, outsourcing and asset optimization. This update is known as Collaborative MES or C-MES. The purpose was to create a link between MES and other business operation areas, including supply focused systems, customer focused systems such as CRM, performance focused systems such as ERP and BI software.
WHAT DOES A
MANUFACTURING
EXECUTION SYSTEM DO?
PRODUCT TRACKING & GENEALOGY
CUSTOMER FOCUSED:
CRM, Service Management
DISPATCHING PRODUCTION UNITS
SUPPLY FOCUSED:
Procurement SCP
LABOR MANAGEMENT
COMPLIANCE FOCUSED:
Doc Management ISO EH&S
QUALITY MANAGEMENT
CONTROLS:
PLC, DCS
DATA COLLECTION & ACQUISITION
PROCESS MANAGEMENT
LOGISTICS FOCUSED:
TMS, WMS
PERFORMANCE ANALYSIS
PRODUCT FOCUSED:
CAD/CAM PLM
RESOURCE ALLOCATION & STATUS
FINANCIAL & PERFORMANCE FOCUSED:
ERP, BI
C-MES
WHAT IS A MANUFACTURING EXECUTION SYSTEM (MES)? | PAGE 4
2008 MESA MODEL
In 2008, the model was expanded to its current version. This model covers enterprise-level strategic initiatives, business operations, plant operations and actual production, creating a link between the different levels and disciplines within manufacturing and production and providing a platform for mutual understanding and planning for improved performance. Originally, in order for a system to be considered an MES, it must have all of the functional groups included in the model. This new model acts as an intermediary between automation and corporate management; it is an integration hub for information throughout a corporation.
WHAT DOES A
MANUFACTURING
EXECUTION SYSTEM DO?
STRATEGIC INITIATIVES
LEAN
MANUFACTURING
QUALITY &
REGULATORY
COMPLIANCE
PRODUCT
LIFESTYLE
MANAGEMENT
REAL
TIME
ENTERPRISE
ASSET
PERFORMANCE
MANAGEMENT
ADDITIONAL
INITIATIVES
+
BUSINESS OPERATIONS
CUSTOMER
FOCUSED:
CRM, Service
Management
FINANCIAL &
PERFORMANCE
FOCUSED:
ERP, BI
PRODUCT
FOCUSED:
CAD/CAM
PLM
COMPLIANCE
FOCUSED:
Doc Management
ISO EH&S
SUPPLY
FOCUSED:
Procurement
SCP
ASSET
RELIABILITY
FOCUSED:
EAM, CMMS
OBJECTIVES
RESULTS
QUERY
DATA
MANUFACTURING/PRODUCTION OPERATIONS
PRODUCT
TRACKING
&
GENEALOGY
RESOURCE
ALLOCATION
&
STATUS
PERFORMANCE
ANALYSIS
PROCESS
MANAGEMENT
DATA
COLLECTION
&
ACQUISITION
QUALITY
MANAGEMENT
LABOR
MANAGEMENT
DISPATCHING
PRODUCTION
UNITS
LOGISTICS
FOCUSED:
TMS, WMS
CONTROLS:
PLC, DCS
EVENTS
EVENTS
MANUFACTURING/PRODUCTION
MANUFACTURING EXECUTION SYSTEM ARCHITECTURE
The ANSI/ISA-95 is an international standard for the integration of enterprise and control systems.
The ANSI/ISA-95 merged the MESA-11 model with the Purdue Reference Model to create a functional hierarchy for MES. As you can see in the infographics on the next page, MES was established at intermediate level three, falling between ERP and process control.
WHAT IS A MANUFACTURING EXECUTION SYSTEM (MES)? |
PAGE 6
MES ISA-95
MES is a functional layer between business planning and logistics and the process control systems in manufacturing. Using real-time workflow visibility, flexibility, and the insights provided by this technology will help decision makers improve the efficiency and quality on factory floors.
MANUFACTURING EXECUTION SYSTEM ARCHITECTURE
LEVEL 4
BUSINESS PLANNING & LOGISTICS
Plant Production Scheduling, Business Management, etc
Establishing the basic plant schedule – production, material use, delivery, and shipping. Determining inventory levels.
TIME FRAME: Months, weeks, days, shifts
LEVEL 3
MANUFACTURING OPERATIONS MANAGEMENT
Dispatching Production, Detailed Production Scheduling, Reliable Assurance, etc
Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.
TIME FRAME: Shifts, hours, minutes, seconds
LEVEL 2
MANUFACTURING CONTROL
Basic Control, Supervisory Control, Process Sensing, Process Manipulation, etc
LEVEL 1
Sensing the production process, manipulating the production process.
LEVEL 0
The physical production process.
Monitoring, supervisory control and automated control of the production process.
THE POSITION OF MES AS PER THE
ISA-95 FUNCTIONAL HIERARCHY
MES is a functional layer between business planning and logistics and the process control systems in manufacturing. Using real-time workflow visibility, flexibility, and the insights provided by this technology will help decision makers improve the efficiency and quality on factory floors. There are certain industries that will benefit further from an MES. The material traceability makes MES technology invaluable to manufacturers who must adhere to strict regulations. This includes food and beverage, automotive, medical device, and aeronautics and aerospace industries. This is because MES documents processes, events and actions, and proof of these is often required when manufacturing regulated products. Our site includes further resources on how MES can benefit certain industries, including automotive and food and beverage.
MANUFACTURING EXECUTION
SYSTEM ARCHITECTURE
Position of MES as per the ISA-95 functional hierarchy.
LEVEL
4
BUSINESS
PLANNING
& LOGISTICS
ERP
LEVEL
3
MANUFACTURING
OPERATIONS
MANAGEMENT
MES
LEVEL
0/1/2
BATCH CONTROL
CONTINUOUS
CONTROL
DISCRETE
CONTROL
PROCESS CONTROL
SYSTEMS
WHAT IS A MANUFACTURING EXECUTION SYSTEM (MES)? | PAGE 8
WHAT ARE THE BENEFITS OF USING A MANUFACTURING EXECUTION SYSTEM?
If you’re considering an MES, it’s important to understand all the benefits it will bring your business.
Here are some examples of how your plant or factory will benefit from an MES:
PAPERLESS MANUFACTURING
ERP INTEGRATION
REDUCES WASTE AND IMPROVES EFFICIENCY
DECREASES DOWNTIME
REDUCES COSTS
REDUCES INVENTORY
WHAT IS A MANUFACTURING EXECUTION SYSTEM (MES)? |
PAGE 9
WHAT ARE THE BENEFITS OF USING A MANUFACTURING EXECUTION SYSTEM?
Paperless Manufacturing
With an MES, labor, scrap, downtime and maintenance are all recored in real-time from the plant floor. This allows you to keep record of all the various costs without using paper notes and spreadsheets. It also helps collect useful data to evaluate unprofitable business models and forecast future prices. MES provides you with the information needed to increase productivity and efficiency on your plant floor.
ERP Integration
An MES allows you to integrate with other systems as shown in the MESA model. This eliminates the need for stand-alone systems and mindless data re-entry, while providing more accurate projections of delivery dates and improving decision making through more accurate data collection.
Reduces Waste and Improves
Efficiency
A key benefit of using an MES is its precision in analyzing production lines and finished products. It can detect any inconsistencies on the shop floor, immediately halting them to reduce wasted material and help businesses cut down on unnecessary expenses.
Decreases Downtime
An MES creates realistic production schedules and tracks raw materials and parts inventory. This eliminates time wasted from re-configuring schedules while parts are in transit. This can be applied to employees too, effectively scheduling the staff you have available.
Reduces Costs
An MES provides you with real-time data on all your operations. Using this real-time data to inform decisions on the product, time and labor required to complete a job, you can streamline operations and improve efficiency. This process eventually enables you to save costs on orders and frees up personnel from operation production lines and controlling inventory.
Reduces Inventory
An MES constantly updates your inventory records with new production, materials, and products. This provides insights directly to your purchasing, shipping and scheduling departments, so they know what is available and what needs to be ordered. Transporting, warehousing and monitoring goods is expensive. The MES ensures you have the right amount of inventory on hand while minimizing surplus at all times.
All of these activities contribute to a more efficient workforce, increased quality, and delivering higher profitability. There are also different types of MES available, each with their own advantages and disadvantages, including SaaS-based software. We have a range of resources on our website that expand on the different types of MES and how they influence business operations.
WHAT IS A MANUFACTURING EXECUTION SYSTEM (MES)? |
PAGE 10
We’ve covered the benefits of using a Manufacturing Execution System, but how do you know it’s the right fit for your business? If you’re looking for more information on how MES could benefit you, start with this comprehensive MES guide.
MES for Dummies
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